Powder Coater - Q file.pdf - National Qualification Register

QUALIFICATION FILE

1

Revised Application Documentation: Version 1 /24 October, 2016

CONTACT DETAILS OF SUBMITTING BODY

Name and address of submitting body:

Paints and Coatings Skill Council,

105, Kakad Chambers, 132, Dr. Annie Besant Road, Worli, Mumbai – 400 018

Name and contact details of individual dealing with the submission

Name: Mamka Hakim

Position in the organisation: Manager Standards & QA

Address if different from above

Tel number(s)

+91-22-2493-1790

+919619459653

E-mail address

[email protected]

List of documents submitted in support of the Qualifications File

1. Occupation Map

2. RFP for development of National Occupational Standards

3. GC Resolution for formation of NOS Sub-committee and its composition

4. Approval of QP/ NOSs

5. List of companies and Industry associations participated and validated QP/NOS

6. Mapping of Manpower skills in the Paints and Coatings Industry

7. Function Analysis

NSDA Reference

To be added by NSDA

QUALIFICATION FILE

2

SUMMARY

Qualification Title and Code: Powder Coater, PCS/Q5102

Body/bodies which will award the

qualification:

Paints and Coatings Skill Council

Body which will accredit providers

to offer the qualification:


Body/bodies which will be

responsible for assessment:


Occupation(s) to which the

qualification gives access:

Industrial Paint Application

The Powder Coater is responsible for painting metal surfaces, particularly, home appliances, auto parts, control panels, furniture, heavy machinery, hospital equipment, office stationary, etc. The individual at work assesses the metal section; understands colour, chemistry required by the customer; prepares part for powder application; and coats it using appropriate tools and machines to achieve the desired finish as per company’s standards or customer’s requirements. The job requires the individual to: undertake physical labour; work in a paint-redolent environment, have good eye-sight and no colour blindness and work in all types of weather conditions.

Proposed level of the qualification

in the NSQF:

4

Anticipated volume of

training/learning required to

complete the qualification:

240 hours.

Entry requirements /

recommendations:

10th

Standard

Minimum 1 year as helper to Powder Coater

Progression from the qualification: Powder Coater, with experience and acquiring additional qualifications can become QC & Testing Supervisor – Powder Coating

Planned arrangements for RPL: Will be done at a place where required lab facility is available.

International comparability where

known:

Not established.

Formal structure of the qualification:

Title of NOS/unit or other component

Mandatory/ Optional

Estimated size (learning hours)

Level

PCS/N5105 Prepare for coating Mandatory 20 4

PCS/N5106 Pre-treat the section to be coated Mandatory 56 4

PPCS/N5109 Perform powder coating Mandatory 60 4

PCS/N5108 Maintain jigs, tools and machines Mandatory 40 4

PCS/N9901 Coordinate with colleagues and/ or customers

Mandatory 12 4

PCS/N9902 Maintain standards of product/ service quality

Mandatory 22 4

QUALIFICATION FILE

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PCS/N9903 Maintain OH&S standards and follow environmental norms

Mandatory 22 4

PCS/N9904 Maintain IPR of organisation and customers

Optional 8 4

Please attach any document giving further detail about the structure of the qualification – eg a Curriculum or Qualification Pack. Give details of the document here: Qualification pack Annexure 1, Model curriculum Annexure 2

QUALIFICATION FILE

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SECTION 1 ASSESSMENT

Body/Bodies which will carry out assessment: Aspiring Minds, Cindrel, Cocubes, MCG Will the assessment body be responsible for RPL assessment? Yes

Give details of how RPL assessment for the qualification will be carried out and quality assured. RPL will be based on the same Qualification Pack and Assessment Criteria mentioned in the QP. Describe the overall assessment strategy and specific arrangements which have been put in place to ensure that assessment is always valid, consistent and fair and show that these are in line with the requirements of the NSQF:

Standardised assessment criteria developed by PCSC. Selected Assessment bodies have been vetted for capability and robust system/ procedure. Question bank of Assessment bodies reviewed and vetted by technical experts/ SMEs employed by PCSC. Assessment to be done only by certified assessors who have undergone ToA program. To follow tablet based assessments except when this is not possible (example due to poor net access, digital illiteracy. Video evidence of the assessment.

Please attach any documents giving further information about assessment and/or RPL.

Give details of the document(s) here: Refer page 1 for the list of attachments.

QUALIFICATION FILE

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ASSESSMENT EVIDENCE

Complete a grid for each grouping of NOS, assessment unit or other component as listed in the entry on the structure of the qualification on page 1.

PCS/N5105 Prepare for coating

Performance Criteria Total

Marks

(400)

Out of Theory Skills

Practical

Studying the

drawing and

production

plan

PC1. study the plan for powder coating

50

3.5 1 2.5

PC2. study the assembly of the metal segment to be coated

3.5 1 2.5

PC3. disassemble the segment if it has multiple pieces to be coated seperately

3.5 1 2.5

PC4. remove the pieces which are made up of rubber, plastic, etc.

3.5 1 2.5

Studying the

coating

required

PC5. understand the conditions where segment is to be used, hot, wet, friction

3.5 1 2.5

PC6. study the metal and chemistry required, e.g., pure epoxy, epoxy polyester, pure polyester, polyurethane

3.5 1 2.5

PC7. colour of paint and finish required 3.5 1 2.5

Verifying

details with

PC8. document the colour, finish and chemistry required, process description and time and effort estimated for the process

3.5 1 2.5

Job Role : Powder Coater Qualification Pack : PCS/Q5102 Sector Skill Council : Paints and Coatings

Guidelines for Assessment

1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each

Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also

lay down proportion of marks for Theory and Skills Practical for each PC.

2. The assessment for the theory part will be based on knowledge bank of questions created by the SSC.

3. Individual assessment agencies will create unique question papers for theory part for each candidate

at each examination/training center (as per assessment criteria below)

4. Individual assessment agencies will create unique evaluations for skill practical for every student at

each examination/training center based on this criteria

5. To pass the Qualification Pack , every trainee should score a minimum of 60% in every NOS

6. In case of successfully passing only certain number of NOS's, the trainee is eligible to take subsequent

assessment on the balance NOS's to pass the Qualification Pack.

QUALIFICATION FILE

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the customer

PC9. meet the customer at appropriate time

3.5 1 2.5

PC10. present the fact file document to the customer and seek approval

3.5 1 2.5

PC11. make necessary changes after discussion and take approval to start the process

4 1.5 2.5

Preparing the

jigging

PC12. select the size of jigs for hanging the segments to be prepared for coating

4 1.5 2.5

PC13. hang segments on the jigs 3.5 1 2.5

PC14. check the controls to see if jigs conveyour is in good working condition

3.5 1 2.5

POINTS 50 15 35

TOTAL POINTS 50

PCS/N5106 Pre treat the section to be coated


Marks

(400)


Practical

Cleaning the

surface

PC1. use brush to remove dust from the corners

50

3 1 2

PC2. fix the buffing pad 3 1 2

PC3. pour the chemical for cleaning onto the buffing pad

3 1 2

PC4. switch on the buffer 3 1 2

PC5. clean the surface by moving buffer machine on the component surface in circular motion

3 1 2

Loading

sections on

conveyor

PC6. load the tanks with chemical and check the concentration of chemicals

3 1 2

PC7. hang the components on jigs and move towards the pre-treatment tanks

3 1 2

PC8. set the control of jigs, conveyor speed and temperature

4 1.5 2.5

Pre-treating for

powder

coating

PC9. dip component in alkaline/acid cleaners to degrease the section

4 1.5 2.5

PC10. rinse the metal in water 4 1.5 2.5

PC11. dip the component in activation solution to convert any chemical on the metal surface to fumes

4 1.5 2.5

PC12. dip the component in phosphatising/ chromating solution to remove rust and formation of blue-grey layer to prevent the metal for corrosion or oxidation

4 1.5 2.5

PC13. final chemical rinse as passivation treatment for further enhancing the anti-corrosion performance of the metal

3 1 2

PC14. dry metal with hot air 3 1 2

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PC15. perform cloth test to check moisture 3 1 2

POINTS 50 17.5 32.5

TOTAL POINTS 50

PCS/N5109 Perform powder coating


Marks

(400)

Out of Theory Skills Practical

Powder

coating the

sections

PC1. set controls of spray gun movements

50

4 1 3

PC2. set sensors to ensure uniform powder delivery rate

4 1 3

PC3. set conveyor speed 4 1 3

PC4. powder coat the parts by spray guns adjusting the pressure on the fluid container and size of fluid orifice

5 1 4

Quality

checking of

powder

coated

sections

PC5. measure microns of thickness of powder coating using micro-meter

5 1 4

PC6. tape test to ensure adhesion of paint on surface

5 1 4

PC7. visual check to see colour and finish of sections

5 2 3

PC8. compare the painted sections with the sample provided

4 1 3

Curing of

coated section

PC9. calibrate the oven temperature and timer

3 1 2

PC10. set conveyor in motion or use batch curing by moving sections inside the oven at temperature and for time as per company’s standards

2 0.5 1.5

Assembling of

parts and

dispatching

PC11. clean the sections to remove dust 3 0.5 2.5

PC12. assemble the parts of the component, as required

3 1 2

PC13. pack the component and dispatch 3 1 2

POINTS

50 13 37

TOTAL POINTS

50

PCS/N5108 Maintain jigs and parts


Marks

(400)


Practical

Maintaining PC1. remove surface oils from tank using oil skimmers

50 6 2 4

QUALIFICATION FILE

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pre-treatment

bath and Paint

booth

PC2. remove particles from the bottom of the tank using bag filtration

7 3 4

PC3. remove emulsified and suspended oils using ultrafiltration or centrifugation

6 2 4

PC4. remove deposits from paint booths 7 3 4

Maintaining

tools and

equipment

PC5. clean powder hoses 6 2 4

PC6. remove deposits from powder guns 6 2 4

PC7. clean jigs after the process is over 6 2 4

PC8. clean the facility regularly 6 2 4

POINTS 50 18 32

TOTAL POINTS 50

PCS/N9901 Coordinate with colleagues and/or customers


Marks

(400)


Practical

Interacting with

superior

PC1. receive job order and instructions

from reporting superior

50

0.5 0.0 0.5

PC2. understand the work output

requirements, targets, performance indicators

and incentives

2.0 0.5 1.5

PC3. deliver quality work on time and

report any anticipated reasons for delays 2.0 0.5 1.5

PC4. escalate unresolved problems or

complaints to the relevant senior 2.0 0.5 1.5

PC5. communicate maintenance and repair

schedule proactively to the superior 2.0 0.5 1.5

PC6. receive feedback on work standards 1.0 0.0 1.0

PC7. document the completed work

schedule and handover to the superior 2.0 0.5 1.5

Communicating

with colleagues

PC8. exhibit trust, support and respect to

all the colleagues in the workplace 1.0 0.25 0.75

PC9. aim to achieve smooth workflow 2.0 0.5 1.5

PC10. help and assist colleagues with

information and knowledge 1.0 0.0 1.0

PC11. seek assistance from the colleagues

when required 1.0 0.25 0.75

PC12. identify the potential and existing

conflicts with the colleagues and resolve 1.0 0.25 0.75

PC13. pass on essential information to

other colleagues on timely basis 1.0 0.0 1.0

PC14. maintain the etiquette, use polite

language, demonstrate responsible and

disciplined behaviours to the colleagues

2.0 0.5 1.5

QUALIFICATION FILE

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PC15. interact with colleagues from

different functions clearly and effectively on

all aspects to carry out the work among the

team and understand the nature of their work

1.0 0.25 0.75

PC16. put team over individual goals and

multi task or share work where necessary

supporting the colleagues

2.0 0.0 2.0

PC17. highlight any errors of colleagues, help

to rectify and ensure quality output 1.0 0.25 0.75

PC18. work with cooperation, coordination,

communication and collaboration, with

shared goals and supporting each other’s

performance

1.0 0.0 1.0

Communicating

effectively with

customers, if

required

PC19. ask more questions to the

customers and identify their needs 1.0 0.25 0.75

PC20. possess strong knowledge on the

product, services and market 2.0 0.5 1.5

PC21. brief the customers clearly on

potential costs and hazards 1.0 0.25 0.75

PC22. communicate with the customers in

a polite, professional and friendly manner 1.0 0.25 0.75

PC23. build effective but impersonal

relationship with the customers 0.5 0.25 0.25

PC24. ensure the appropriate language

and tone are used with customers 1.0 0.25 0.75

PC25. listen actively and have a two way

communication 1.0 0.25 0.75

PC26. be sensitive to the gender, cultural

and social differences such as modes of

greeting, formality, etc.

1.0 0.25 0.75

PC27. understand the customer

expectations correctly and provide the

appropriate products and services

2.0 0.5 1.5

PC28. understand the customer

dissatisfaction and address or escalate their

complaints effectively

2.0 0.5 1.5

PC29. maintain a positive, sensible and

cooperative manner all time 1.0 0.25 0.75

PC30. ensure to maintain a proper body

language, dress code, gestures and etiquettes

towards the customers

1.0 0.25 0.75

PC31. avoid interrupting the customers while

they talk 1.0 0.0 1.0

PC32. ensure to avoid negative questions

and statements to the customers 1.0 0.0 1.0

PC33. inform the customers on any issues or

problems before hand and also on the

developments involving them

2.0 0.5 1.5

QUALIFICATION FILE

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PC34. ensure to respond back to the

customer immediately for their voice

messages, e-mails, apps, etc.

1.0 0.0 1.0

PC35. develop good rapport with the

customers and promote other products and

services

2.0 0.5 1.5

PC36. seek feedback from the customers on

their understanding to what was discussed 1.0 0.0 1.0

PC37. explain the terms and conditions clearly 2.0 0.5 1.5

POINTS 50 10 40

PCS/N9902 Maintain standards of product/ service quality


Marks

(400)


Practical

Engaging with

superior or

customers to

understand

product/

service quality

requirements

PC1. keep in mind the profiles of

expected customers

50

2.0 0.5 1.5

PC2. understand the target customers and

their product/ service quality requirements as

defined by the company

3.0 0.5 2.5

PC3. receive superior’s/ customer

feedback regularly 2.0 0.0 2.0

PC4. aim to build a good connect with the

customers through quality product/ service 2.0 0.5 1.5

PC5. keep tab on frequent discussions with

regular customers on general likes and

dislikes in the market, latest trends, customer

expectations, etc.

2.0 0.5 1.5

PC6. receive updates on regular feedbacks

from the clients on current service,

complaints, and improvements to be made,

etc.

2.0 0.5 1.5

PC7. if necessary, compulsively seek

customer rating of product/ service in order

to help develop a set of regularly improved

procedures

2.0 0.5 1.5

PC8. demonstrate quality orientation at

all level 4.0 1.5 2.5

PC9. aim to gain their long lasting loyalty

through satisfaction 3.0 1.0 2.0

Achieving

100% customer

satisfaction for

given quality

PC10. ensure 100% customer satisfaction

via product/ service quality 3.0 0.5 2.5

PC11. treat the customers fairly and with

due respect 3.0 0.5 2.5

PC12. focus on executing company’s

marketing strategies and product

development needs

3.0 1.0 2.0

PC13. focus on enhancing brand value of

company by maintaining or enhancing quality 3.0 1.0 2.0

QUALIFICATION FILE

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standards

Fulfilling

customer

requirement

PC14. ensure that customer expectations

are met 2.0 0.5 1.5

PC15. learn to read customers’ needs and

wants 2.0 0.5 1.5

PC16. willingly accept and implement new

and innovative products and services that

help improve customer satisfaction

3.0 1.0 2.0

PC17. communicate feedback of customer

to senior, especially, the negative feedback 2.0 0.5 1.5

PC18. maintain close contact with the

customers and focus groups 2.0 0.5 1.5

PC19. offer promotions to improve

product satisfaction level to the customers

periodically

3.0 1.0 2.0

PC20. weigh the cost of fulfilling

unscheduled customer requests, consult with

senior and advise the customer on

alternatives

2.0 0.5 1.5

POINTS 50 13 37

PCS/N9903 Maintain O&HS standards and follow environmental norms

Performance Criteria

Total

Marks

(400)


Practical

Taking

precautionary

measures to

avoid health,

safety and

environmental

hazards

PC1. assess the various health, safety and

environmental hazards in the work areas

50

1.5 0.4 1.1

PC2. take necessary steps to eliminate or

minimize the hazards 1.0 0.4 0.6

PC3. analyze the causes of accidents at the

workplace 1.5 0.4 1.1

PC4. suggest measures to prevent such

accidents from taking place 1.5 0.4 1.1

PC5. take preventive measures to avoid

risk of burns and other injury due to contact

with hot surfaces, gas, fire, hot fluids/ liquids,

etc.

1.5 0.4 1.1

PC6. suggest methods to improve the

existing safety procedures at the workplace 1.5 0.4 1.1

PC7. dispose waste in the designated

areas safely as per company’s policies and

rules

1.5 0.4 1.1

PC8. maintain appropriate ventilation in

the rooms while there is more exposure to

paint vapours

1.0 0.4 0.6

PC9. avoid dumping unused cans to

safeguard the environment 1.0 0.0 1.0

Following PC10. be aware of the locations of fire 1.0 0.4 0.6

QUALIFICATION FILE

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standard

health, safety

and

environmental

policies and

procedure

extinguishers, emergency exits, etc.

PC11. practice correct emergency

procedures 1.5 0.4 1.1

PC12. check and review the storage areas

frequently 1.5 0.4 1.1

PC13. stack items in an organized way and

use safe lifting techniques to reduce risk of

injuries from handling procedures at the

storage areas

1.5 0.4 1.1

PC14. ensure to be safe while handling

materials, tools, acids, chemicals, equipment,

etc.

1.0 0.4 0.6

PC15. store the chemicals and acids in a

well-ventilated and locked areas with warning

signs displayed

1.5 0.4 1.1

PC16. ensure safe techniques while

moving furniture and fixtures 1.5 0.4 1.1

PC17. ensure to reduce risk of injury from

use of electrical tools 1.5 0.4 1.1

PC18. read the manufacturer’s manual

carefully before use of any equipment 1.0 0.0 1.0

PC19. unplug the electrical equipment

before performing maintenance 1.0 0.4 0.6

PC20. keep the floors free from oil, water

and grease to avoid slippery surface 1.0 0.4 0.6

PC21. use rubber mats in the places where

floors are constantly wet 1.0 0.0 1.0

PC22. ensure safety from injuries of cuts

to loss of fingers, while handling sharp

hazardous tools and equipment

1.5 0.4 1.1

PC23. use flat surfaces, secure holding and

protective wear while using such sharp tools 1.5 0.4 1.1

PC24. use health, safety and

environmental protection practices for

storing, cleaning, and maintaining tools,

equipment, and supplies

1.5 0.4 1.1

PC25. practice ergonomic lifting, bending,

or moving equipment and supplies 1.5 0.4 1.1

PC26. identify the requirement for

maintaining environmental norms 1.0 0.4 0.6

PC27. comply with the environmental

safety norms while on work to prevent

accidents and health hazards

1.0 0.4 0.6

PC28. follow company policies and rules

regarding use of hazardous materials to avoid

health, safety and environmental impacts

caused by them

1.0 0.4 0.6

Using safety

tools or

PC29. ensure the employees have access

to first aid kit when needed 1.0 0.0 1.0

QUALIFICATION FILE

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Personal

Protective

Equipment

PC30. ensure all equipment and tools are

stored and maintained properly and safe to

use

1.0 0.4 0.6

PC31. ensure to use personal protective

equipment and safety gear such as gloves,

mask, headwear, footwear, glasses, goggles,

etc. for specific tasks and work conditions

where required

1.5 0.4 1.1

PC32. ensure to display safety signs at

places where necessary for people to be

cautious

1.5 0.4 1.1

PC33. ensure electrical precautions such

as insulated clothing, adequate equipment

insulation, dry work area, switch off the

power supply when not required, etc.

1.5 0.4 1.1

PC34. ensure availability of general health

and safety equipment such as fire

extinguishers, first aid equipment, safety

equipment, clothing, safety installations such

as fire exits, exhaust fans, etc.

1.5 0.4 1.1

Achieving

health, safety

and

environmental

standards

PC35. document all the first aid

treatments, inspections, etc., conducted to

keep track of the safety measures undertaken

1.0 0.4 0.6

PC36. document all the environmental

hazards caused and the measures undertaken

to comply with the established safety

procedures of the workplace

1.0 0.0 1.0

PC37. report to the supervisor on any

problems and hazards identified and any

breach of environmental procedures.

1.0 0.4 0.6

PC38. ensure zero accident at workplace 1.0 0.4 0.6

PC39. adhere to safety standards and

ensure no material damage 1.0 0.4 0.6

PC40. take necessary action and correct any

environmental hazards caused 1.0 0.4 0.6

POINTS 50 14 36

PCS/N9904 Maintain IPR of organisation and customer


Marks

(400)


Practical

Securing

company’s IPR

PC1. prevent leak of new plans and

designs to competitors by reporting on time

50

7.0 0.0 7.0

PC2. be aware of any of company’s

product or design patents 8.0 1.0 7.0

PC3. report IPR violations observed in the 8.0 2.0 6.0

QUALIFICATION FILE

14

market, to supervisor or company head

Respecting

customer’s

copyright

PC4. read copyright clause of the

material published on the internet and any

other printed material

8.0 0.5 7.5

PC5. protect infringement upon

customer’s business or design plans 8.0 2.0 6.0

PC6. consult supervisor or senior

management when in doubt about using

information available from customer

6.0 0.0 6.0

PC7. report any infringement observed by

anyone in the company 5.0 0.0 5.0

POINTS 50 5.5 44.5

TOTAL POINTS 50

QUALIFICATION FILE

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SECTION 2

SUMMARY EVIDENCE OF LEVEL

Qualification Title and Code : Powder Coater PCS/Q5108

Process required Professional

knowledge

Professional skill Core skill Responsibility Level

Dissemble the segment to be painted. Prepare jigging. Clean surface. Load sections on conveyor. Pre-treat work surface, powder coat and finish the surface.

Knowledge of paint chemistry, assembling and dissembling of components for painting, process of pre-treatment, coating and curing; jig preparation and quality standards of customer or OEM.

Practical skills to prepare jigs, dissemble and assemble components, perform pre-treatment, powder coating and curing as per quality standards, maintain pre-treatment bath, paint booth, tools and equipments every time repetitively in a routine.

Ability to read instructions by paint manufacturers, controls and machines. Communicate issues related to quality and standard procedure to supervisor.

Responsible for assessing the metal section; understanding colour, chemistry required by the customer; preparing part for powder application; and coating it using appropriate tools and machines to achieve the desired finish.

4

Level: 4 Level: 4 Level: 4 Level: 4 Level: 4

QUALIFICATION FILE

16

SECTION 3

EVIDENCE OF NEED

What evidence is there that the qualification is needed? Information was gathered from industry interactions and data from desk research to arrive at metrics for estimation of current and future employment in the sub-sector and its further break-down for each job role including this one. Please refer to meetings notes and occupation maps. This enabled prioritization of the development of the qualification packs.

What is the estimated uptake of this qualification and what is the basis of this estimate?

Information gathered from industry interactions, Occupation Map and Functional Analysis for the skill gap

between the industry demand institutional supply - provide the basis for estimated uptake. This is the basis

for planning training with the industry and training providers.

What steps were taken to ensure that the qualification(s) does/do not duplicate already existing or

planned qualifications in the NSQF?

NSDC QRC has already checked this.

What arrangements are in place to monitor and review the qualification(s)? What data will be used and at what point will the qualification(s) be revised or updated? NOS Sub-committee inputs are sought from time-to-time as needed to check the relevance of QP/NOSs, and the revision exercise is undertaken, as needed. The qualification will be revised or updated on 31

st March, 2018

Please attach any documents giving further information about any of the topics above. Give details of the document(s) here: Refer page 1 for the list of attachments.

QUALIFICATION FILE

17

SECTION 4

EVIDENCE OF RECOGNITION AND PROGRESSION

What steps have been taken in the design of this or other qualifications to ensure that there is a clear path to other qualifications in this sector? Vertical mobility options are available in the Occupation map. Powder Coater, with experience and acquiring additional qualifications can become QC & Testing Supervisor – Powder Coating.

Please attach any documents giving further information about any of the topics above. Give details of the document(s) here:

Occupation Map Refer page 1 for the list of attachments

Powder Coater - Q file.pdf - National Qualification Register

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Powder Coater - Q file.pdf - National Qualification Register